Consecutively wound or stacked battery cells

ABSTRACT

The specification discloses a consecutively wound or stacked battery system and a method for making these devices. In one aspect, battery cells are wound consecutively, separated by insulating layers, to form an integral battery system capable of producing multiple voltages. In a second, but related, aspect, multiple battery cells are wound consecutively on a large diameter mandrel, cut in a radial plane, and laid flat to form stacked battery systems capable of producing multiple voltages. Whether remaining in the consecutively wound configuration, or being cut to become a stacked cell configuration, each cell in these configurations may be selectively coupled to other cells within its consecutive winding or stack to produce desired output voltages and current ratings. In the case of the stacked battery system, this battery system may be selectively cut to provide amperage capacities to order. Moreover, the consecutively wound or stacked battery systems may also include capacitors, fuel cells, and the like, wound in the same fashion.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable.

BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] The preferred embodiments of the present invention are directedto batteries. More particularly, the preferred embodiments of thepresent invention are directed to consecutively wound or stacked batterycells and battery systems.

[0005] 2. Description of the Related Art

[0006] It is common in the battery industry to build battery cells bywinding long sheets of anode material and cathode material, separated bya porous layer, around a mandrel to form a generally circular singlecell battery. After the winding process completes, some form of liquidor viscous electrolyte is inserted, usually into a hole at the center ofthe circular winding, and the electrolyte is allowed to fill the porouslayer between the anode and the cathode sheets. U.S. Pat. No. 4,975,095to Strickland et al. exemplifies a method and related system forperforming the related art winding of a cell, with the central opening72 of the winding (see FIG. 6) being the location where liquidelectrolyte is forced into the winding. Windings for battery cells neednot be circular however. U.S. Pat. No. 6,190,794 to Wyser is exemplaryof a system where the winding is non-circular, in this case elliptical,as is the disclosure of U.S. Pat. No. 5,746,780 to Narukawa, et al.

[0007] Whether circular or elliptical, related art battery windings areonly a single cell, and therefore only operate at a single voltage;however, many modem electronic devices need multiple voltages to operatecorrectly. U.S. Pat. No. 6,038,473 (hereinafter the '473 patent) toOlson et al. describes a defibrillator battery pack in which one set ofindividual battery cells is used to charge the defibrillator, and asecond set of individual battery cells is used to produce an operatingvoltage for control electronics. In the defibrillator application, andin any related art application requiring multiple voltages, the relatedart approach has been to provide individual battery cells connected inparallel and/or series as necessary to supply the voltages and currentsrequired. In cases where high initial currents are required, for examplein-rush current associated with starting electrical motors and the like,individual capacitor cells may likewise be wired in parallel with thebattery cells to supply the needed starting current. However, batterysystems with multiple voltages achieved by connecting a plurality ofindividual battery cells are expensive to build.

[0008] When providing multiple voltages for electronic devices, orwiring capacitors in parallel with battery cells to meet currentdemands, the battery cells and capacitors of the related art areconnected by coupling wires from the individual components (batterycells and capacitors), and then coupling the wires to terminals of anexternal casing such that all the internal components are within onebattery pack. However, there are still multiple battery cells, andpossibly capacitors, within the battery pack. As can be appreciated fromthis description, assembling battery packs in this manner is very laborintensive, thus contributing to the expense of construction.

[0009] The capacitor industry has made multiple capacitors in a singlewinding, as exemplified in U.S. Pat. No. 4,028,595 (hereinafter the '595patent) to Stockman. In particularly, the '595 patent discloses thatmultiple sheets of dielectric material with metal film on one side arerolled together on a mandrel to create a first capacitor. After windinga number of turns, a portion of the metal film on each of the sheets ofdielectric material is removed, yet the windings are continued with thesame dielectric sheets. Additional pieces of dielectric material may beplaced between the sheets starting at the location where the portion ofthe metal on each sheet is removed. In this way, two capacitors,possibly with different voltage ratings, that share dielectric materialare produced with a single winding. While it is possible to buildcapacitors that share dielectric material, the electrolyte of differentbatteries may not be shared between battery cells.

[0010] A second, but related, problem faced by the battery industry isproviding batteries of correct amperage capacity. That is, while anybattery may have at its output terminals a necessary voltage, thebattery may not have the amperage capacity to hold the rated terminalvoltage at required amperage demands. The solution of the related art isto couple a plurality of individual batteries in parallel until thetotal amperage capacity of the battery system matches that of theintended load. This procedure too is labor intensive, and requiresbattery manufacturers to have significant stocks of batteries of varyingcapacity to meet possible demand.

[0011] Thus, what is needed in the art is a mechanism to provide anintegral unit multiple cell battery without the need of externallyconnecting multiple single cell batteries to produce the desiredvoltages and currents.

BRIEF SUMMARY OF SOME OF THE PREFERRED EMBODIMENTS

[0012] The problems noted above are solved in large part by aconsecutively wound or stacked battery system in which a plurality ofdevices are constructed by consecutively winding those devices on top ofeach other to produce a multiple device system in a single integralunit. The multiple devices could be battery cells, fuel cells,capacitors and the like. More particularly, the preferred embodimentsare directed to consecutively wound lithium battery cells having solidpolymer electrolyte, each battery cell separated by an insulating layerthat extends beyond an anode or cathode layer in each of the batterycells. Once the requisite number of cells are wound into theconsecutively wound system, the axial or rolled ends of theconsecutively wound system are preferably coated or shooped with aconductive material. A portion of this conductive material is preferablyremoved by brushing such that the conductive material cannot providecontinuity from one cell to another. Thus, each battery cell in theconsecutively wound unit is electrically isolated from other batterycells. By the use of external jumpers between the battery cells at theshooping, the plurality of consecutively wound battery cells can beconnected in any series or parallel fashion to produce desired voltagesand currents.

[0013] In an alternative, but related, embodiment of the preferredembodiments, the consecutively wound battery system is wound on acylindrical mandrel having a large (for example, two to five foot)diameter mandrel. The process is continued as described with respect tothe previous paragraph; however, once the winding is complete theconsecutively wound battery is cut on one side along the radial planeintersecting an axis of the winding. The cut consecutively wound batteryis then laid flat to produce a substantially rectangular shaped stackedbattery system. While it is possible to use the stacked battery systemdirectly, preferably the stacked battery is cut along its width toproduce a desired length, and thus a desired capacity. Additionally, asubstantially rectangular shaped battery may also be cut, either duringthe winding process or thereafter, to a particular width as a furtheradjustment of the capacity. One consecutively wound battery system cutto become a stacked battery may produce many battery systems havingvarying voltages (by coupling in parallel or series the plurality ofbatteries in the stack) and current capacities (by cutting to produce aparticular length, width or both) as needed or required.

[0014] The disclosed devices and methods comprise a combination offeatures and advantages which enable it to overcome the deficiencies ofthe prior art devices. The various characteristics described above, aswell as other features, will be readily apparent to those skilled in theart upon reading the following detailed description, and by referring tothe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] For a detailed description of the preferred embodiments,reference will now be made to the accompanying drawings in which:

[0016]FIG. 1 shows a simplified perspective end view of a plurality ofconsecutively wound battery cells of the preferred embodiment;

[0017]FIG. 2 shows a perspective view of the battery system of FIG. 1with the battery cells removed along their axis;

[0018]FIG. 3 shows the cross-section of one turn of layered material ofa battery cell;

[0019]FIG. 4A shows a cross-section of a portion of the windings of atwo battery cell consecutively wound battery system;

[0020]FIG. 4B shows, in graphical form, another way to couple twobattery cells of a consecutively wound battery system;

[0021]FIG. 4C shows, in graphical form, a way to couple two batterycells of a consecutively wound battery system;

[0022]FIG. 5A shows, in graphical form, another way to couple threebattery cells of a consecutively wound battery system;

[0023]FIG. 5B shows, in graphical form, another way to couple threebattery cells of a consecutively wound battery system;

[0024]FIG. 6A shows, in graphical form, a way to couple four batterycells of a consecutively wound battery system to produce two outputvoltages;

[0025]FIG. 6B shows, in graphical form, a way to couple four batterycells of a consecutively wound battery system to selectively provide asingle voltage or two voltages;

[0026]FIG. 6C shows, in graphical form, a way to couple four batterycells of a consecutively wound battery system to produce two outputvoltages having varying amperage capacities;

[0027]FIG. 7A shows a cross-sectional view of a consecutively woundbattery system having two battery cells separated by an insulatinglayer;

[0028]FIG. 7B shows the system of FIG. 7A after shooping has takenplace;

[0029]FIG. 7C shows the system of FIG. 7B with a portion of the shoopingremoved to electrically isolate each battery cell;

[0030]FIG. 8 shows a consecutively wound battery system laid flat tobecome a stacked battery system;

[0031]FIG. 9 shows a cross-section of a battery cell of the preferredembodiment;

[0032]FIG. 10 shows a cross-sectional view of a consecutively woundbattery where the anode and cathode are not offset, or are onlyminimally offset, using a dielectric lane technique; and

[0033]FIG. 11 shows a perspective view of a stacked battery systemcomprising several strands or ropes.

NOTATION AND NOMENCLATURE

[0034] Certain terms are used throughout the following description andclaims to refer to particular system components. This document does notintend to distinguish between components that differ in name but notfunction. In the following discussion and in the claims, the terms“including” and “comprising” are used in an open-ended fashion, and thusshould be interpreted to mean “including, but not limited to . . . ”.

[0035] Also, the term “couple” or “couples” is intended to mean eitheran indirect or direct electrical connection. Thus, if a first devicecouples to a second device, that connection may be through a directelectrical connection, or through an indirect electrical connection viaother devices and connections.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] The preferred embodiments are directed to consecutively wound orstacked battery cells and battery systems. The battery cells of thevarious embodiments described herein were developed in the context oflithium metal coated anodes and cathodes with solid polymer electrolyte.The solid polymer electrolyte is described in detail in copendingapplication Ser. No. 09/388,741 (Attorney Docket No. 1860-00100) titled,“Solid Polymer Electrolyte”, now U.S. Pat. No. ______, which isincorporated by reference as if reproduced in full below. The lithiummetal anode and cathode current collectors, and how anode and cathodewindings are electrically coupled, are described in detail in copendingapplication Ser. No. 09/388,733 (Att'y Docket No. 1860-00200) titled“All Solid State Electrochemical Device and Method of Manufacturing,”now U.S. Pat. No. ______, which is incorporated by reference as ifreproduced in full below. Because of the context of development, thevarious embodiments are described with regard to battery cells havingthe solid polymer electrolyte construction. However, the description inthis manner should not be construed as a limitation of the invention toonly battery cells with solid polymer electrolytes, as the method andstructures described herein may be used with any wound combination ofweb substrates such as lithium metal cells, lead acid cells,nickel-cadmium, nickel-metal-hydride, alkaline, zinc air, and the like.Further, and as will be described more fully below, the methods andstructures are equally applicable to devices such as film capacitors,electrochemical capacitors, fuel cells, and the like.

[0037] The preferred embodiments are directed to consecutively wound orstacked battery systems. The process of building a consecutively woundor stacked battery system preferably starts by winding of the variouslayers of a first battery cell around a mandrel. Once the proper lengthof battery cell material has been wound (the length corresponding tocapacity of the cell), the winding material is cut using knowntechniques to create a first battery cell of the winding. After wrappingat least one full turn of insulating material, a second battery cell iswound over the first cell. The process continues for any number ofbattery cells, each layer wound consecutively over the previous layer.Thus a multiple cell, yet single or integral unit, battery is produced.

[0038]FIG. 1 shows a simplified perspective end view of a plurality ofconsecutively wound or stacked battery cells of the preferredembodiments. In particular, FIG. 1 shows an innermost cell 10, a middlecell 12, and an outermost cell 14. As can be seen in FIG. 1, the variouscells are wound together to form an integral unit 2 having multiplebattery cells. FIG. 2 shows a perspective view of the integral batteryunit 2 of FIG. 1 with the cells shifted about their common axis 16 toexemplify how the cells of the preferred embodiment are substantiallycoaxial in their placement. It must be understood that the battery cells10, 12, 14 of the preferred embodiment are not separable as shown inFIG. 2, but that FIG. 2 merely exemplifies the preferred coaxial natureof the consecutively wound battery cells. While three battery cells areexemplified in FIGS. 1 and 2, any number of consecutively wound batterycells may be used and still be within the contemplation of thisinvention. Further, and as discussed below, devices other than batterycells may be consecutively wound or stacked, e.g. capacitors and fuelcells, and these too would be within the contemplation of thisinvention. Further still, the windings need not be circular asexemplified in FIGS. 1 and 2. The various cell layers may beconsecutively wound around any suitable shape such as elliptical,rectangular, and the like, or the windings deformed to any suitableshape after removal from the mandrel.

[0039]FIGS. 1 and 2 provide a high level overview of the preferredarrangements for the consecutively wound cells of the preferredembodiments. FIG. 3 shows an exemplary cross-sectional view of onebattery cell, taken substantially along lines 3-3 of FIG. 2. Althoughtaken along line 3-3 of FIG. 2, cutting the outermost battery cell 14,the description that follows is equally applicable to any of the batterycells present. FIG. 3 shows that each turn of the exemplary battery cellis made up of a plurality of layers of material. Though FIG. 3 showsonly the cross-section of one turn to simplify the drawings, any numberof turns may be used for a particular cell, depending upon the desiredamperage capacity and the diameter of the winding. The battery cellcomprises at least an anode layer 18, an electrolyte layer 20, and acathode layer 22 which are preferably as thin as possible. Usingtechnology in existence at the time of writing this specification, theselayers may be as small as 0.2 microns each; however, as film technologyadvances, the thickness of sheets of material may become thinner, andpreferably the thinnest layers available are preferred. In the mostpreferred embodiments, the anode layer 18 is a lithium coated plasticsheet, the electrolyte layer 20 is preferably a solid polymerelectrolyte, and the cathode layer 22 is preferably a lithium coatedplastic sheet, as described more fully in the application Ser. Nos.09/388,741 and 09/388,733 incorporated by reference herein. The layersof material that make up the battery cell of the preferred embodimentsusing film technology in existence as of the writing of thisspecification may be less than 30 microns thick, meaning that tens,hundreds or thousands of turns may be used depending on the diameter ofthe winding and the desired amperage capacity of the particular batterycell.

[0040] Consider for purposes of explanation a consecutively woundbattery system having two battery cells, a cross-section of a portion ofthe windings of the two cells exemplified in FIG. 4A. Thus, portion 24represents the cross-section of a first battery cell (that may comprisehundreds or thousands of turns, and portion 26 represents thecross-section of a second battery cell (that may also comprise hundredsor thousands of turns) separated by an insulating layer 64). Each of theportions 24, 26 comprises at least an anode layer 18, an electrolytelayer 20 and a cathode layer 22. Because in an embodiment the anode andcathode layers extend beyond the electrolyte layer, there are twopossible configurations for the multiple cell battery having two batterycells—the anode layers extending in the same axial direction (with thecathode layers extending in a second axial direction), or the anodelayer from a first cell extending the same direction as the cathodelayer of the second cell. These configurations allow for severaldifferent advantageous battery solutions from the integral unit multiplecell battery.

[0041] Still referring to FIG. 4A, consider the case where the anodelayers of the first and second cell extend in different directions,anodes marked “A” and cathodes marked “C.” By electrically coupling theanode and cathode on one axial end, a series connection is made. If thepreferred lithium battery is used, each cell generates approximately 3.6Volts. By connecting the batteries in series, a battery system producingapproximately 7.2 Volts is achieved. FIG. 4B represents the seriescombination in a graphical form with jumper 28 representing theelectrical coupling of an anode and cathode on one axial end.

[0042] Now consider the consecutively wound two cell battery systemwhere the anodes and cathodes of the battery cells extend in the samedirection, as exemplified in FIG. 4C (again using the short-handnotation). By electrically coupling the anodes, exemplified by jumper30, and electrically coupling the cathodes, exemplified by jumper 32, abattery system is created having a total amperage capacity equal to thesum of the two battery cells. The battery cells in the configurations ofFIGS. 4B and 4C need not necessarily be coupled at all. Indeed, it ispossible that each cell may be used independently. If the battery cellsare not intended to be coupled into a series or parallel connection, itis also possible that each of these cells may have varying amperagecapacities. This could be useful, for example, if the device operated bythe multiple cell battery has critical and non-critical devices.

[0043] Although any number of cells may be wound together in the mannerdescribed, consider a set of three cells, exemplified graphically inFIG. 5A. By selectively coupling anodes to cathodes, as exemplified byjumpers 34 and 36, in the three cell system, a series connection ismade. If the preferred lithium cells are used, each cell producingapproximately 3.6 Volts, then the system shown in FIG. 5A produces anoverall voltage of 10.8 Volts. FIG. 5B exemplifies a three battery cellsystem in which only two of the three cells are coupled in parallel,jumpers 38 and 40, thus producing an integral battery unit havingvoltage sources with different amperage capacities. Likewise, FIG. 6Agraphically exemplifies a consecutively wound or stacked battery havingfour cells jumpered in such a way that two output voltages are provided.If each of the cells is a lithium cell producing approximately 3.6Volts, then the integral unit consecutively wound battery produces twoindependent 7.2 Volt sources. FIG. 6B exemplifies a four cell integralunit battery that can be switched between balanced two-source operationand series operation. With switch 42 closed, the system produces 14.4Volts from the negative terminal 44 to the positive terminal 46. Withswitch 42 open, a 7.2 Volt supply is produced between terminals 44 and48, and another 7.2 Volt supply is produced between terminals 50 and 46.FIG. 6C graphically exemplifies yet another configuration. If each ofthe cells of the multiple cell battery exemplified in FIG. 6C is capableof generating 400 milliamps of current, what is provided is a multiplecurrent battery system with 400 milliamps provided at terminals 52 and54, and 1200 milliamps provided at terminals 56 and 58. The examplesgiven in FIGS. 4(B, C), 5(A, B) and 6(A-C) are merely exemplary. One ofordinary skill in the art, now understanding how the consecutively woundbattery cells may be connected in series and parallel combinations couldeasily devise many equivalent combinations that are not explicitly shownin these examples. Moreover, any number of cells may be consecutivelywound or stacked, and therefore two or more consecutively wound batterycells may be provided and may be connected and interconnected in manydifferent ways to produce many operating voltages and operatingcurrents.

[0044] Each battery cell of the consecutively wound battery systemcomprises a plurality of turns of the layered anode/electrolyte/cathodematerial. Referring again to FIG. 3, preferably the anode layer orlayers 18 are offset in a first axial direction (the axis 16 directionis shown in FIG. 3, but is not intended to be to scale or in properrelationship to the center of the winding of the exemplary battery cell)and the cathode layer or layers are offset in a second axial direction.Thus, traditional electrical current flow (which is opposite of electronflow) preferably leaves the battery cell from the anode layer 18, andenters the battery cell through the cathode layer 22. However, giventhat each battery cell may comprise tens, hundreds, or even thousands ofturns, and further that the thickness of each of the anode and cathodelayers may only be less than few microns thick, preferably, electricalcontact is not made at only a single location of the otherwisecontinuous anode material extending beyond the electrolyte. Likewise,current flowing back to the battery preferably does not enter at asingle point along the otherwise continuous cathode layer extendingbeyond the electrolyte. Rather, the portions of the anode layerextending beyond the electrolyte are preferably electrically connectedby the use of some form of conductive coating. Likewise, the portions ofthe cathode layer extending beyond the electrolyte are also preferablyelectrically coupled using a conductive coating.

[0045] For purposes of explaining how the conductive coating couples thevarious turns of each battery cell, and likewise may couple differentbattery cells within the same consecutively wound battery system,reference is now made to FIG. 7A. FIG. 7A shows a cross-sectional viewof a consecutively wound battery system having two battery cells 60 and62, each battery cell 60, 62 having an exemplary two turns. Preferably,a layer of insulating material 64 is disposed between each battery cell(preferably a sheet of polyester), and that layer of insulating material64 preferably extends at least 0.5 millimeter beyond the offset of theanode and cathode material. Though FIG. 7A is merely a cross-section ofa winding, it will be understood that the insulating material 64preferably makes at least one complete wrap around the consecutivelywound battery system. Referring to the upper or outermost battery cell60 of FIG. 7A, inasmuch as the anode material extending beyond theelectrolyte is a continuous sheet, it would be possible to merely tap orelectrically contact the windings at one location, for example location66, and extract current from the battery cell 60. However, tapping theotherwise continuous anode at one location may be difficult to do giventhe relatively small thickness of the anodes (and cathodes), and furthertapping at only a single location may result in significant heating andresistance losses. Rather, axial or rolled ends of the consecutivelywound battery system are preferably coated with a sprayed-on metalcoating, a process known as shooping, as described in the copendingapplication Ser. No. 09/388,733 incorporated by reference herein. Theend-coating could equivalently be accomplished with conductiveadhesives, conductive epoxies, solder paste or other functional means.It is also possible that the various anode and cathode turns could beconnected by physical means, for example by tab welding a plurality oftabs connected at the anode and/or cathode in various locations, butthis is not preferred.

[0046]FIG. 7B exemplifies the consecutively wound battery system afterthe preferred shooping has taken place, but prior to any further steps.In particular, FIG. 7B shows that each of the axial or rolled ends arecovered by conductive shooping material 68. Inasmuch as the shoopingmaterial is preferably conductive, it may be seen that the twoindependent battery cells 60 and 62 of FIG. 7B are effectively connectedin parallel after shooping alone. If it is desired that the batteries inthis configuration be connected in parallel, then no further steps needbe taken with respect to the shooping material save the coupling of theshooping to the terminals of the battery, which may be done usingaluminum, copper or nickel wires using known techniques. Preferably,however, the shooping material is not left in the configurationexemplified in FIG. 7B, and instead, a portion of the shooping materialis removed.

[0047] Removing the shooping material preferably comprises brushing eachaxial end of the shooped consecutively wound battery system, which wipesaway or removes portions of the shooping material. By brushing the axialor rolled ends of the consecutively wound battery system in this manner,the various cells may be electrically isolated from each other acrossthe layer of insulating material 64.

[0048]FIG. 7C shows the two cell consecutively wound battery system witha portion of the shopping material removed. In particular, the shoppingmaterial extending beyond the insulating layer 64 in each direction ispreferably removed by the brushing procedure, ultrasonic cleaning orknife trimming. Brushing machines suitable for performing this task maybe purchased from Midland Machine Company of Carpenterville, Ill. 60110U.S.A., Arcotronics Italia SpA, 40037 Sasso Marconi (BO) Italy, 2AS.R.L., Bologna Italy, Metar Machines—Montena Components SA, Fribourg,Switzerland. What preferably remains is the shooping materialelectrically coupling, for example, all the anode layers of the upperbattery cell 60, and likewise all the anode layers of the lower batterycell 62, but because the shooping has been brushed off at least as fardown as the end of the layer of insulating material 64, preferably noshooping extends across that insulating barrier, and thus these anodesare now electrically isolated. An equivalent description applies to theshooping material 68 on the side where the cathodes extend beyond theelectrolyte.

[0049] The embodiments shown in FIGS. 7A-C are constructed by offsettingthe anode and cathode material. A second embodiment for coupling theturns of a battery cell, and also coupling battery cells to each otherin the stacked configuration, is shown in FIG. 10. In this secondembodiment, the anode and cathode material is offset only slightly, orpreferably not at all. In this way, the shooping 68 electricallycontacts the anode and cathode layers on both sides. In order that thebattery cells not be shorted by the shooping, however, a series ofdielectric lanes 90 are preferably manufactured into the anode andcathode sheets such that the portion of the anode or cathode in contactwith the shopping 68 is electrically isolated from the portion of theanode or cathode in contact with the electrolyte. This electricalisolation is possible because of the construction of the anode andcathode sheets.

[0050] The anode and cathode sheets used to create battery cells of thepreferred embodiment are formed on sheets or meshes of insulatingmaterial such as polyester. The sheets or meshes are then coated withthin layers of metal, the precise type of metal depending on thechemistry of the battery cell. The lithium battery cells of thepreferred embodiment are described in detail in copending applicationSer. Nos. 09/388,741 and 09/388,733. Referring again to FIG. 10, anodesheets comprise an insulating material 92 coated with at least one metallayer 94. The dielectric lane 90 thus comprises a portion of metal layer94 removed, or preferably not deposited during the coating process.Thus, while anode metal 94 may electrically contact the shooping 68 onboth sides, it is electrically isolated on one side from the portion ofthe metal in contact with the electrolyte (labeled “E” in FIG. 10).Having the shooping contact both the anode and cathode on each sideprovides better mechanical strength of the stacked battery system,better handles swelling caused by temperature fluctuations, and providesbetter heat dissipation. Also, the arrangement where little or no offsetof the layers is required provides many additional manufacturingbenefits in the stacked configuration, discussed more fully below.

[0051] If it is known in advance the electrical configuration desiredfor the consecutively wound battery system (series connections, parallelconnections), it is possible to selectively add different sizes ofinsulating material (axial lengths) to implement the desired system. Forexample, and referring again to FIG. 4B, if it is known in advance thata series connection is to be made, then the layer of insulating material64 may be of selected axial length and placement on the wound systemsuch that it does not extend far beyond the electrolyte layer betweenthe two battery cells in one axial direction. On the rolled end wherethe insulating material does not extend, shooping alone may be all thatis needed to couple the cathode and the anode (the shooping materialacts as the jumper 28). In this exemplary case of FIG. 4B, however, theother axial end (where the positive and negative terminals need toconnect), preferably has the insulating material extending as described,and the brushing removes excess so as to electrically isolate the twoterminals. Preferably, however, the insulating layers between eachconsecutively wound battery cell extend beyond the anode and/or cathodelayers in both directions, and each end is preferably brushed so as toelectrically isolate the anodes and cathodes of each consecutively woundbattery cell. To the extent any cell or cells need to be connected for aparticular application, this is preferably done by wires or otherelectrical conductors connecting the various portions of shoopingmaterial. In this way, especially for the higher order consecutivelywound battery systems (having three or more battery cells), the preciseset-up of the consecutively wound battery system need not be determineduntil a customer makes an order, the order filled from a previouslywound, shooped and brushed system.

[0052] Construction of a consecutively wound battery system preferablystarts by winding a plurality of layers of a battery cell initiallyaround a mandrel, winding at least one turn of insulated material, andthen winding another battery cell layer around the first cell andinsulating material, and so on until the desired number of cells havebeen wound. Preferably thereafter, the consecutively wound batterysystem is removed from the mandrel and the shooping process performed.In one embodiment, this mandrel may have a relatively small diameter,for example less than one centimeter. In a second embodiment, however,the mandrel diameter may be large, on the order of two to five feet, butpreferably three feet. After winding a plurality of battery cells andshooping as described, in this embodiment the consecutively woundbattery system is preferably cut on one side along a radial planeintersecting the axis of the winding and laid flat. The consecutivelywound battery is thus conformed to be a substantially flat or stackedbattery system. All the previous discussion regarding the many ways inwhich the various cells of such a stacked battery may be connected stillapply, except that the battery is now stacked instead of consecutivelywound (although it was preferably built in a consecutively wound fashionfirst). While a stacked battery system in this size may find applicationdirectly (approximately twelve feet in length if wound on a three footdiameter mandrel), preferably the stacked system is used to providebatteries having custom amperage ratings.

[0053]FIG. 8 exemplifies a stacked cell battery system 70 constructedusing the technique whereby the anode and cathodes are offset from eachother, rather than the dielectric lane technique which is discussedbelow. In particular, FIG. 8 shows an upper cell 80 (which may have beenan outermost cell wrapped around the mandrel during the wrappingprocess), a center cell 82 and a bottom cell 84 (which bottom cell mayhave been an innermost cell wrapped around the mandrel in the windingprocess). Separating each of the layers of cell material are insulatinglayers 64 (which may also be present beneath the lower battery cell 84and above the uppermost cell 80, but are not shown to simplify thedrawing). As discussed with respect to the consecutively wound batterysystems, preferably each axial end of the stacked battery is shooped,and then a portion of that shooping removed such that the anode andcathode layers extending beyond the electrolyte for each battery cellare electrically coupled, with the cells separated by the insulatinglayer. In particular, FIG. 8 shows shooping 68 on the near face of theperspective view of FIG. 8, shooping 68 separated by the layers ofinsulating material 64. As the configuration stands in FIG. 8, it may bepossible to take positive traditional current flow from a positiveterminal 86 for the uppermost battery cell 80, and return current to thebattery cell 80 by way of the negative terminal 88, and so on for theremaining cells.

[0054] What should be understood with respect to FIG. 8 is thatregardless of the length (labeled L in the drawings) or the width(labeled W in the drawings), the battery voltage is still the same. Ifthe battery cell of use is the preferred lithium cell having a solidpolymer electrolyte, then the voltage developed between the positiveterminal 86 and the negative terminal 88 will be approximately 3.6Volts. The length and width parameters, however, control the batterycapacity or amperage rating. That is, the length and width of thebattery in this configuration (and the same parameters in a circularform for the consecutively wound configuration) control how much currenteach particular battery cell is capable of delivering. Thus, the stackedbattery system exemplified in FIG. 8 presents the possibility of customcapacity batteries. In particular, the stacked battery could be made onthe large diameter mandrel and flattened as shown in FIG. 8, and thencut in varying sizes, depending upon orders from customers for batterysystems. Not only is it possible to provide multiple voltages byselectively jumpering the individual battery cells, but it is alsopossible to provide varying amperage capacities for those multiplevoltages.

[0055] For purposes of illustration, consider that the stacked batterysystem exemplified in FIG. 8 has a one unit width (W=1) and a twelveunit length (L=12), and in this configuration each cell is capable ofproviding 1200 milliamps of current at rated voltage. Thus, if eachbattery cell is the preferred lithium cell, then the stacked batterysystem is capable of providing three independent sources of 3.6 Voltpower at 1200 milliamps. Consider though that a customer desires a 10.8Volt system having the capability of providing 1200 milliamps. In such acircumstance, the twelve unit length stacked battery system of FIG. 8could be cut, for example along dashed line 89, to have a four unitlength, and then each of the battery cells connected in series toprovide the required 10.8 Volts. That is, by cutting the exemplarysystem at a four unit length, each battery cell thus becomes capable ofproviding 400 milliamps at 3.6 Volts. By connecting the cells in series,it is possible to achieve the desired 10.8 Volts at the required 400milliamps of current. Because in the preferred embodiment the shoopingbetween each respective layer is brushed off so as to isolate thelayers, it will be required to provide physical jumpers between theshooping layers to achieve the series connections of this example.Further, cutting of the stacked battery across its width (to achieve adesired length) needs to be accomplished in such a way that the anodesand cathodes of the various battery cells do not short with each otheror across their respective electrolytes. Cutting of the stacked cell inthis manner is preferably accomplished by laser etching, but mayequivalently take place by electrode arcing or physical sawing.

[0056] What is important to realize from the above example, however, isthat although a portion of the overall stacked battery system was cut toprovide a desired voltage and current rating (a four unit length), theremaining stacked battery system (in the exemplary case having aremaining eight unit length), is still available for use, which mayinvolve further cutting for other custom amperages and voltages. Thus,this embodiment has particular commercial attractiveness as multiplebatteries, of various voltages and amperages, may be produced from asingle stacked battery system.

[0057] The discussion with regard to FIG. 8 assumed a constructionconfiguration of shifted anode and cathode layers. In this shifted anodeand cathode configuration, it would not be possible to cut the stackedsystem along its length (to produce a particular width) and shoop thecut edges, because in so doing, the anode, cathode and electrolyte wouldhave no offset. Shooping the cut edge in this circumstance would shortthe anodes, cathodes and electrolytes. However, using the dielectriclane technique, it is possible that the stacked battery system may becut at predetermined widths, in addition to cutting to a desired length,which further adds to the manufacturing flexibility of the stackedbattery system. FIG. 11 shows a perspective view of a stacked batterythat may be cut along its length (to produce a desired width) inaddition to cutting along its overall width (to produce a desiredlength) using the dielectric lane technique. In particular, thisembodiment is constructed similar to that exemplified in FIG. 8—windingthe various cell layers over a large diameter mandrel, and cutting thewinding to be laid flat. However, prior to winding, the number andrespective widths of the battery strips or ropes (labeled 95, 96 and 97in FIG. 11) are determined. Thereafter, the anode and cathode sheets(not individually shown in FIG. 11) are masked and coated formingdielectric lanes proximate to the desired widths. In the exemplarystacked battery of FIG. 11 having three strips or ropes, each sheet(anode or cathode) will have three sets (a set being a dielectric laneon top and bottom of the sheet in registration) of dielectric lanes. Asthe sheets of anode and cathode material are rolled on the mandrel,preferably razors cut the sheets (as well as the insulating material asit is fed to the mandrel between cells), for example along dashed lines98 and 99 of FIG. 11.

[0058] Referring again briefly to FIG. 10, it is seen that theelectrolyte layers, labeled “E,” are bounded as to width by thedielectric lanes 90. Building a stacked multiple cell, multiple strandstacked battery using the dielectric lane technique thus implies thatelectrolyte sheets are preferably cut to an appropriate width prior towinding, and then fed to the winding process at the appropriate location(centered between dielectric lanes in each strand or rope). Once woundand cut to be laid flat, the various strands or ropes are separated (inthe exemplary system of FIG. 11 along dashed lines 98 and 99) and thenshooped. Each strand or rope thereafter has a cross-section similar toFIG. 10. Depending on the desired amperage capacity, each rope may becut again to have a particular length, with the remaining portionavailable to fill subsequent orders.

[0059] The description of the embodiments above discloses that a batterycell comprises at least an anode layer, an electrolyte layer, and acathode layer. While a consecutively wound or stacked battery systemhaving battery cells of this nature would indeed be operational,preferably, however, each battery cell effectively comprises two cells.FIG. 9 shows a cross-section of a single turn of a battery cell of thepreferred embodiment. In particular, the preferred battery cellcomprises a double-sided anode layer 100 in the center between twodouble-sided cathode layers 102A, B. Between the double sided anodelayer 100 and each double-sided cathode layer 102A, B resides anelectrolyte layer 104A,B respectively. Effectively, the layeredmaterials of FIG. 9 are two independent battery cells sharing an anode100. The upper double-sided cathode layer 102A is shown in FIG. 9 indashed lines to exemplify that this layer is preferably not anindependent sheet fed to the rolling process, but is actually the samedouble-sided cathode layer as 102B except on the next revolution.Throughout this specification, and also in the claims, reference to awound or stacked battery cell in a battery system should be read toinclude not only the minimum required layers for a battery cell (anodelayer, cathode layer, and electrolyte layer), but also should be read toinclude battery cell systems such as that exemplified in FIG. 9.Depending upon the requirements for any particular wound or stackedbattery system, it may be further possible to have each battery cell (asthat term is used) to include any number of stacked layers sharinganodes and/or cathodes in the manner exemplified in FIG. 9.

[0060] As discussed in the Background section, it may also be desirablein some situations to wire batteries in parallel with capacitors, forexample to supply starting currents for motors and the like. One of theembodiments of the present invention contemplates a multiple wound orstacked battery systems that comprises a wound or stacked battery celland also comprises a wound or stacked capacitor. Stated otherwise, anyof the consecutively wound battery cells discussed herein could bereplaced with a consecutively wound or stacked capacitive cellconstructed in much the same way. Thus, the shooping and/or externaljumpers between isolated shooped regions may be used to couplecapacitors in parallel with battery cells in consecutively woundsystems. In addition to, or in place of, any of the battery cellsdiscussed herein, fuel cells could be used to supply current, and thistoo would be within the contemplation of this invention. A fuel cell isan electrochemical energy conversion device that converts hydrogen andoxygen into electricity and heat. Fuel cells can be recharged while inoperation. Fuel cells are similar in construction to a battery in thatsingle cell and bipolar anode/electrolyte/cathode designs are employed.A wide variety of flexible substrates such as catalyzed membranes ofhydrophobized porous carbon paper, carbon cloth, or polymer films aresandwiched between flexible anode and cathode collector plates.Preferably, the fuel cell or fuel cell stack is the first windings ofthe consecutively wound unit. By being the first winding, a winding corecan be used that is constructed in such a way as one end to serve asanode and cathode vent exits and the other opposite end as the anode andcathode entry feeds. Further, a completed and encased cylindrical oroval finished fuel cell could serve as the base core or mandrel for thesecondary or multiple consecutively wound battery or capacitor windings.Alternatively, a cylindrically shaped encased fuel cell could serve asthe outermost portion of the consecutively wound unit, whereby the innervacant hole is occupied by consecutively wound batteries and/orcapacitors.

[0061] The above discussion is meant to be illustrative of theprinciples and various embodiments of the present invention. Numerousvariations and modifications will become apparent to those skilled inthe art once the above disclosure is fully appreciated. For example, itwas discussed above that in addition to lithium batteries having solidpolymer electrolyte as battery cells, that battery cells using viscouselectrolyte or fuel cells could be used. In this case, it may benecessary to provide access to the electrolyte layers for filling (inthe case of the viscous electrolyte), as well as the exit of flue gasduring the charging process. In such a circumstance, it is possible thatrather than metal end-spraying or shooping an entire axial or rolled endof the consecutively wound battery system, that only a portion may beshooped to allow this access, and this too would be within thecontemplation of this invention. Relatedly, if a fuel cell is added tothe consecutively wound or stacked battery in addition to or in place ofone of the battery cells, it may be necessary for oxygen to enter thesystem, and partially shooping one or both of the axial ends couldaccomplish this task. Throughout the discussion of the preferredembodiments above, it is discussed that the consecutively wound batterysystem had an axis, implying that the winding takes place such that thewound battery system has a circular cross-section; however, while thisis preferred, it is not required and thus any winding of battery cells,fuel cells, capacitive layers, and the like in which these variouslayers are consecutively wound on top of each other would be within thecontemplation of this invention. Further, in cases where a parallelconfiguration of batteries is desired, it is possible that separatebattery cells of the consecutively wound system could share anode orcathode layers, or both. The preferred method of producing the stackedbattery system is by winding the various cells, and then cutting thewinding to produce the stacked version; however, it is possible, andwithin the contemplation of this invention, to create the stacked systemby building the stack directly. It is intended that the following claimsbe interpreted to embrace all such variations and modifications.

What is claimed is:
 1. A method of producing a multiple cell battery,the method comprising: winding a first battery cell a plurality of turnsaround a mandrel; and winding a second battery cell a plurality of turnsaround the first battery cell.
 2. The method as defined in claim 1further comprising coupling the first and second battery cells inseries.
 3. The method as defined in claim 2 further comprising:extending an anode layer of the first battery cell beyond an electrolytelayer of the first battery cell in a first axial direction; extending acathode layer of the first battery cell beyond the electrolyte layer ofthe first battery cell in a second axial direction; extending an anodelayer of the second battery cell beyond an electrolyte layer of thesecond battery cell in the second axial direction; and extending acathode layer of the second battery cell beyond the electrolyte layer ofthe second battery cell in the first axial direction.
 4. The method asdefined in claim 3 further comprising electrically coupling the cathodelayer of the first battery cell to the anode layer of the second batterycell.
 5. The method as defined in claim 4 further comprising: separatingthe first battery cell from the second battery cell by a layer ofinsulating material; extending the insulating material in the firstaxial direction beyond the anode layers of the first battery cell;coating axial ends of the multiple cell battery with conductivematerial; removing a portion of the conductive material from an end inthe first axial direction to electrically isolate the anode layer of thefirst battery cell from the cathode layer of the second battery cell. 6.The method as defined in claim 5 wherein removing a portion of theconductive material further comprises brushing away the conductivematerial until a portion covering the anode layer of the first batterycell is separated from a portion covering the cathode layer of thesecond battery cell by the insulating material.
 7. The method as definedin claim 5 further comprising: extending a portion of the anode layer ofthe first battery cell beyond the electrolyte layer of the first batterycell in the second axial direction, the portion of the anode layerbeyond the electrolyte electrically isolated from the electrolyte layer;extending a portion of the cathode layer of the first battery cellbeyond the electrolyte layer of the first battery cell in the firstaxial direction, the portion of the anode layer beyond the electrolyteelectrically isolated from the electrolyte layer; extending a portion ofthe anode layer of the second battery cell beyond the electrolyte layerof the second battery cell in the first axial direction, the portion ofthe anode layer beyond the electrolyte electrically isolated from theelectrolyte layer; and extending a portion of the cathode layer of thesecond battery cell beyond the electrolyte layer of the second batterycell in the second axial direction, the portion of the cathode layerbeyond the electrolyte electrically isolated from the electrolyte layer.8. The method as defined in claim 5 further comprising: refraining fromextending the anode layer of the first battery cell beyond theelectrolyte layer of the first battery cell in the second axialdirection; refraining from extending the cathode layer of the firstbattery cell beyond the electrolyte layer of the first battery cell inthe first axial direction; refraining from extending the anode layer ofthe second battery cell beyond the electrolyte layer of the secondbattery cell in the first axial direction; and refraining from extendingthe cathode layer of the second battery cell beyond the electrolytelayer of the second battery cell in the second axial direction.
 9. Themethod as defined in claim 1 further comprising coupling the first andsecond battery cells in parallel.
 10. The method as defined in claim 9further comprising: extending an anode layer of the first battery cellbeyond an electrolyte layer of the first cell in a first axialdirection; extending a cathode layer of the first battery cell beyondthe electrolyte layer of the first battery cell in a second axialdirection; extending an anode layer of the second battery cell beyond anelectrolyte layer of the second battery cell in the first axialdirection; and extending a cathode layer of the second battery cellbeyond the electrolyte layer of the second battery cell in the secondaxial direction.
 11. The method as defined in claim 10 furthercomprising: coupling the plurality of turns of the anode layer of thefirst battery cell to create a first terminal of the first battery cell;coupling the plurality of turns of the cathode layer of the firstbattery cell to create a second terminal of the first battery cell;coupling the plurality of turns of the anode layer of the second batterycell to create a first terminal of the second battery cell; and couplingthe plurality of turns of the cathode layer of the second battery cellto create a second terminal of the second battery cell.
 12. The methodas defined in claim 11 further comprising: separating the first batterycell from the second battery cell by a layer of insulating material;extending the insulating material in the first axial direction beyondthe anode layers of the first and second battery cells; extending theinsulating layer in the second axial direction beyond the anode layersof the first and second battery cells; coating ends of the multiple cellbattery with conductive material; and removing a portion of theconductive material from ends of the multiple cell battery in the firstand second axial directions to electrically isolate the first batterycell from the second battery cell.
 13. The method as defined in claim 12wherein removing a portion of the conductive material from ends of themultiple cell battery in the first and second directions to electricallyisolate the first battery cell from the second battery cell furthercomprises brushing away the conductive material from the end of themultiple battery cell until portions of the conductive material coupledto the anode layer of the first battery cell are electrically isolatedfrom portions of the conductive material coupled to the anode layer ofthe second battery cell across the insulating material.
 14. The methodas defined in claim 13 further comprising brushing away the conductivematerial from the end of the multiple battery cell until portions of theconductive material coupled to the cathode layer of the first batterycell are electrically isolated from portions of the conductive materialcoupled to the cathode layer of the second battery cell across theinsulating material.
 15. The method as defined in claim 12 whereinwinding the first and second battery cells further comprises winding oneof the first and second battery cells to have a greater amperagecapacity.
 16. The method as defined in claim 12 further comprising:extending a portion of the anode layer of the first battery cell beyondthe electrolyte layer of the first battery cell in the second axialdirection, the portion of the anode layer beyond the electrolyte layerelectrically isolated from the electrolyte layer; extending a portion ofthe cathode layer of the first battery cell beyond the electrolyte layerof the first battery cell in the first axial direction, the portion ofthe cathode layer beyond the electrolyte layer electrically isolatedfrom the electrolyte layer; extending a portion of the anode layer ofthe second battery cell beyond the electrolyte layer of the secondbattery cell in the second axial direction, the portion of the anodelayer beyond the electrolyte layer electrically isolated from theelectrolyte layer; and extending a portion of the cathode layer of thesecond battery cell beyond the electrolyte layer of the second batterycell in the first axial direction, the portion of the cathode layerbeyond the electrolyte layer electrically isolated from the electrolytelayer.
 17. The method as defined in claim 12 further comprising:refraining from extending the anode layer of the first battery cellbeyond the electrolyte layer of the first battery cell in the secondaxial direction; refraining from extending the cathode layer of thefirst battery cell beyond the electrolyte layer of the first batterycell in the first axial direction; refraining from extending the anodelayer of the second battery cell beyond the electrolyte layer of thesecond battery cell in the second axial direction; and refraining fromextending the cathode layer of the second battery cell beyond theelectrolyte layer of the second battery cell in the first axialdirection.
 18. The method as defined in claim 1 wherein winding thefirst and second battery cells further comprises winding the first andsecond battery cells where at least one the first and second batterycells comprises a solid polymer electrolyte.
 19. The method as definedin claim 1 wherein winding the first and second battery cells furthercomprises winding the first and second battery cells where at least oneof the cells comprises a viscous electrolyte.
 20. The method as definedin claim 19 further comprising injecting the viscous electrolyte afterthe winding steps.
 21. The method as defined in claim 1 furthercomprising winding a third battery cell a plurality of turns around thesecond battery cell.
 22. The method as defined in claim 21 furthercomprising coupling the first, second and third battery cells in series.23. The method as defined in claim 21 further comprising coupling thefirst, second and third battery cells in parallel.
 24. The method asdefined in claim 21 further comprising couple two of the first, secondand third battery cells in parallel.
 25. A structure of a multiple cellbattery comprising: a first battery cell having a plurality of turnsproducing a first voltage; and a second battery cell having a pluralityof turns wound around the first battery cell, the second battery cellproducing a second voltage.
 26. The structure of a multiple cell batteryas defined in claim 25 wherein the first battery cell further comprises:an anode layer; a cathode layer; and an electrolyte layer disposedbetween the anode and cathode layer, the electrolyte layer coupling theanode layer and cathode layer.
 27. The structure of a multiple cellbattery as defined in claim 26 wherein the first battery furthercomprises: said anode layer comprising lithium metal; said cathode layercomprising suitable oxide based coating; and said electrolyte layercomprising a solid polymer electrolyte.
 28. The structure of a multiplecell battery as defined in claim 27 wherein the first battery cellfurther comprises: a double sided cathode layer; a double sided anodelayer; a first electrolyte layer disposed between a first side of thedouble sided cathode layer and a first side of the double sided anodelayer, the first electrolyte layer coupling the double sided cathodelayer to the double sided anode layer; and a second electrolyte layerdisposed between a second side of the double sided cathode layer and asecond side of the double sided anode layer, the second electrolytelayer also coupling the double sided cathode layer to the double sidedanode layer.
 29. The structure of a multiple cell battery as defined inclaim 26 wherein the second battery further comprises: an anode layer; acathode layer; and an electrolyte layer disposed between the anode andcathode layer, the electrolyte layer coupling the anode layer andcathode layer.
 30. The structure of a multiple cell battery as definedin claim 29 wherein the second battery cell further comprises: a doublesided cathode layer; a double sided anode layer; a first electrolytelayer disposed between a first side of the double sided cathode layerand a first side of the double sided anode layer, the first electrolytelayer coupling the first double sided cathode layer to the double sidedanode layer; and a second electrolyte layer disposed between a secondside of the double sided cathode layer and a second side of the doublesided anode layer, the second electrolyte layer also coupling the doublesided cathode layer to the double sided anode layer.
 31. The structureof a multiple cell battery as defined in claim 25 further comprising thefirst and second battery cells coupled in series.
 32. The structure of amultiple cell battery as defined in claim 31 further comprising: ananode layer of the first battery cell exposed for electrical contact ona first end; a cathode layer of the first battery cell exposed forelectrical contact on a second end; a layer of insulation wound at leastone full turn disposed between the first battery cell and the secondbattery cell; an anode layer of the second battery cell exposed forelectrical contact on the second end; a cathode layer of the secondbattery cell exposed for electrical contact on the first end; a firstset of conductive material on the second end electrically contacting thecathode layer of the first battery cell an the anode layer of the secondbattery cell; and a second set of conductive material on the first end,a portion of the second set of conductive material coupled to the anodelayer of the first battery cell and electrically isolated from a portionof the second set of conductive coating coupled to the cathode layer ofthe second battery cell.
 33. The structure of a multiple cell battery asdefined in claim 32 further comprising: a first set of dielectric lanesdefining a portion of the anode layer of the first battery cell exposedfor electrical contact on the second end; a second set of dielectriclanes defining a portion of the cathode layer of the first battery cellexposed for electrical contact on the first end; a third set ofdielectric lanes defining a portion of the anode layer of the secondbattery cell exposed for electrical contact on the first end; and afourth set of dielectric lanes defining a portion of the cathode layerof the second battery cell exposed for electrical contact on the secondend.
 34. The structure of a multiple cell battery as defined in claim 33wherein the first set of conductive material on the second endelectrically contacts the cathode layer and the portion of the anodelayer of the first battery cell, and also electrically contacts theanode layer and the portion of the cathode layer of the second batterycell.
 35. The structure of a multiple cell battery as defined in claim33 wherein the portion of the second set of conductive material coupledto the anode layer of the first battery cell also couples to the portionof the cathode layer of the first battery cell, and wherein the portionof the second set of conductive material coupled to the cathode layer ofthe second battery cell also couples to the portion of the anode layerof the second battery cell.
 36. The structure of a multiple cell batteryas defined in claim 25 further comprising the first and second batterycells coupled in parallel.
 37. The structure of a multiple cell batteryas defined in claim 36 further comprising: an anode layer of the firstbattery cell exposed for electrical contact on a first end; a cathodelayer of the first battery cell exposed for electrical contact on asecond end; a layer of insulation wound at least one full turn disposedbetween the first battery cell and the second battery cell; an anodelayer of the second battery cell exposed for electrical contact on thefirst end; a cathode layer of the second battery cell exposed forelectrical contact on the second end; a first set of conductive materialon the first end, a portion of the first set of conductive materialcoupled to the anode layer of the first battery cell and electricallyisolated from a portion of the first set of conductive coating coupledto the anode layer of the second battery cell by the layer ofinsulation; and a second set of conductive material on the second end, aportion of the second set of conductive material coupled to the cathodelayer of the first battery cell and electrically isolated from a portionof the second set of conductive coating coupled to the cathode layer ofthe second battery cell by the layer of insulation.
 38. The structure ofa multiple cell battery as defined in claim 37 further comprising: afirst set of dielectric lanes defining a portion of the anode layer ofthe first battery cell exposed for electrical contact on the second end;a second set of dielectric lanes defining a portion of the cathode layerof the first battery cell exposed for electrical contact on the firstend; a third set of dielectric lanes defining a portion of the anodelayer of the second battery cell exposed for electrical contact on thesecond end; and a fourth set of dielectric lanes defining a portion ofthe cathode layer of the second battery cell exposed for electricalcontact on the first end.
 39. The structure of a multiple cell batteryas defined in claim 38 wherein the portion of the first set ofconductive material coupled to the anode layer of the first battery cellalso couples to the portion of the cathode layer of the first batterycell, and wherein the portion of the first set of conductive materialcoupled to the anode layer of the second battery cell also couples tothe portion of the cathode layer of the second battery cell.
 40. Thestructure of a multiple cell battery as defined in claim 38 wherein theportion of the second set of conductive material coupled to the cathodelayer of the first battery cell also couples to the portion of the anodelayer of the first battery cell, and wherein the portion of the secondset of conductive material coupled to the cathode layer of the secondbattery cell also couples to the portion of the anode layer of thesecond battery cell.
 41. The structure of a multiple cell battery asdefined in claim 25 further comprising third battery cell having aplurality of turns wound around the second battery cell, the thirdbattery cell producing a third voltage.
 42. A structure of a multiplecell battery comprising: a first battery cell comprising a plurality ofsubstantially rectangular layers rolled to form a cylinder having anaxis; and a second battery cell comprising a plurality of substantiallyrectangular layers rolled coaxially around the first battery cell. 43.The structure of a multiple cell battery as defined in claim 42 whereinthe first battery cell and the second battery cell are coupled inseries.
 44. The structure of a multiple cell battery as defined in claim43 further comprising: an anode layer of the first battery cellextending beyond an electrolyte layer of the first battery cell in afirst axial direction; a cathode layer of the first battery cellextending beyond the electrolyte layer of the first battery cell in asecond axial direction; an anode layer of the second battery cellextending beyond an electrolyte layer of the second battery cell in thesecond axial direction; and a cathode layer of the second battery cellextending beyond the electrolyte layer of the second battery cell in thefirst axial direction.
 45. The structure of a multiple cell battery asdefined in claim 44 further comprising said cathode layer of the firstbattery cell electrically coupled to the anode layer of the secondbattery cell.
 46. The structure of a multiple cell battery as defined inclaim 44 further comprising: a substantially rectangular shapedinsulating layer rolled at least one wrap wound between the first andsecond battery cells, said insulating layer extending beyond the anodelayer of the first battery cell in the first axial direction, and alsoextending beyond the anode layer of the second battery cell in thesecond axial direction; a conductive material at least partially coatingaxial ends of the multiple cell battery, a portion of the coating on anend in the first axial direction coupled to the anode of the firstbattery cell and electrically isolated from a portion of the coatingcoupled to the cathode of the second battery cell.
 47. The structure ofa multiple cell battery as defined in claim 46 wherein the conductivematerial further comprises a conductive shooping material.
 48. Thestructure of a multiple cell battery as defined in claim 42 furthercomprising: an anode layer of the first battery cell extending beyond anelectrolyte layer of the first battery cell in a first axial direction;a cathode layer of the first battery cell extending beyond theelectrolyte layer of the first battery cell in a second axial direction;an anode layer of the second battery cell extending beyond anelectrolyte layer of the second battery cell in the first axialdirection; and a cathode layer of the second battery cell extendingbeyond the electrolyte layer of the second battery cell in the secondaxial direction.
 49. The structure of a multiple cell battery as definedin claim 48 further comprising: a first terminal of the first batterycell coupled to the plurality of turns of the anode layer of the firstbattery cell; a second terminal of the first battery cell coupled to theplurality of turns of the cathode layer of the first battery cell; afirst terminal of the second battery cell coupled to the plurality ofturns of the anode layer of the second battery cell; and a secondterminal of the second battery cell coupled to the plurality of turns ofthe cathode layer of the second battery cell.
 50. The structure of amultiple cell battery as defined in claim 49 further comprising: asubstantially rectangular shaped insulating layer rolled at least onewrap between the first and second battery cells, said insulating layerextending beyond the anode layers of the first and second battery cellsin the first axial direction, and also extending beyond the cathodelayers of the first and second battery cells in the second axialdirection; a conductive material at least partially coating axial endsof the multiple cell battery, a portion of the coating on an end in thefirst axial direction coupled to the anode of the first battery cell andelectrically isolated from a portion of the coating coupled to the anodeof the second battery cell by the insulating layer, and a portion of thecoating on an end in the second axial direction coupled to the cathodeof the first battery cell and electrically isolated from a portion ofthe coating coupled to the cathode of the second battery cell by theinsulating layer.
 51. The structure of a multiple cell battery asdefined in claim 42 wherein at least one of the first and second batterycells further comprises a solid polymer electrolyte.
 52. The structureof a multiple cell battery as defined in claim 51 wherein both the firstand second battery cells comprises a solid polymer electrolyte.
 53. Thestructure of a multiple cell battery as defined in claim 42 wherein oneof the first and second battery cells further comprises a viscouselectrolyte.
 54. The structure of an integral battery system comprising:a first device having a plurality of wound turns; and a second device,independent from the first device, having a plurality of turns woundaround the first device.
 55. The structure of an integral battery systemas defined in claim 54 wherein one of the first and second devices is abattery cell.
 56. The structure of an integral battery system as definedin claim 55 wherein the battery cell is a lithium battery cell having asolid polymer electrolyte.
 57. The structure of an integral batterysystem as defined in claim 55 wherein the battery cell has a viscouselectrolyte.
 58. The structure of an integral battery system as definedin claim 55 wherein one of the first and second devices is a capacitor.59. The structure of an integral battery system as defined in claim 54wherein one of the first and second devices is a fuel cell.
 60. Thestructure of an integral battery system as defined in claim 59 whereinone of the first and second devices is a capacitor.
 61. In a system witha battery cell having an amperage capacity based on a length of thebattery cell, a method of adjusting the amperage of the battery cellcomprising removing a portion of the battery cell such that a remainingportion of the battery cell has the desired amperage capacity.
 62. Themethod of adjusting the amperage capacity of the battery cell as definedin claim 61 wherein removing a portion of the battery cell furthercomprises cutting the battery cell to have a shorter length.
 63. Themethod of adjusting the amperage capacity of the battery cell as definedin claim 62 wherein cutting the battery cell further comprises lasercutting.
 64. The method of adjusting the amperage capacity of thebattery cell as defined in claim 62 wherein cutting the battery cellfurther comprises electrode arcing.
 65. A method comprising: wrapping aplurality of turns of a battery cell to make a wound battery cell;cutting the wound battery cell to create a stacked battery cell, theamperage capacity of the stacked battery cell based on a length of thestacked battery cell; and removing a portion of the length of thestacked battery cell to adjust the amperage capacity of the stackedbattery cell.
 66. The method as defined in claim 65 wherein wrapping aplurality of turns of the battery cell to make the wound battery cellfurther comprises wrapping the plurality of turns of the battery cellaround a substantially cylindrical mandrel thus creating a substantiallycylindrical shaped wound battery cell.
 67. The method as defined inclaim 66 wherein wrapping the plurality of turns of the first batterycell around a cylindrical mandrel further comprises wrapping theplurality of turns of the first battery cell around a mandrel having adiameter of at least two feet.
 68. The method as defined in claim 67wherein wrapping the plurality of turns of the battery cell around amandrel having a diameter of at least two feet further compriseswrapping a plurality of turns of the first battery cell around themandrel having a diameter of at least two feet and less than five feet.69. The method as defined in claim 68 wherein wrapping the plurality ofturns of the battery cell around the mandrel having a diameter of atleast two feet and less than five feet further comprises wrapping thebattery cell around the mandrel having a diameter of approximately threefeet.
 70. The method as defined in claim 66 wherein cutting the woundbattery cell to create a stacked battery cell further comprises: cuttingthe substantially cylindrical shaped wound battery cell on one sidesubstantially parallel with an axis of the cylindrical shape; and layingthe cut substantially cylindrical shaped wound battery to besubstantially flat to become the stacked battery cell with acircumference of the cylindrical shape becoming the length of thestacked battery cell.
 71. In a stacked battery system with a firstbattery cell having an amperage capacity based on a length of the firstbattery cell, and a second battery cell having an amperage capacitybased on a length of the second battery cell, a method of adjusting theamperage capacity of the first and second battery cells comprisingremoving a portion of the length of the first and second battery cellssuch that a remaining portion of each of the first and second batterycells has the desired amperage capacity.
 72. The method of adjusting theamperage capacity of the first and second battery cells as defined inclaim 71 wherein removing a portion of the length of the first andsecond battery cells further comprises cutting the stacked batterysystem to have a shorter length.
 73. The method of adjusting theamperage capacity of the first and second battery cells as defined inclaim 72 wherein cutting the battery cell further comprises lasercutting.
 74. The method of adjusting the amperage capacity of the firstand second battery cells as defined in claim 72 wherein cutting thebattery cell further comprises electrode arcing.
 75. A methodcomprising: wrapping a plurality of turns of a first battery cell;wrapping a plurality of turns of a second battery cell around the firstbattery cell to make a consecutively wound battery system; cutting theconsecutively wound battery system to create a stacked battery system,the amperage capacity of each cell of the stacked battery system basedon a length of the stacked battery system; and removing a portion of thelength of the stacked battery system to adjust the amperage capacityeach cell of the stacked battery system.
 76. The method as defined inclaim 75 wherein the wrapping steps further comprise: wrapping theplurality of turns of the first battery cell around a substantiallycylindrical mandrel; and wrapping the plurality of turns of the secondbattery cell around the first battery cell, thus creating asubstantially cylindrical shaped wound battery system.
 77. The method asdefined in claim 76 wherein wrapping the plurality of turns of the firstbattery cell around a substantially cylindrical mandrel furthercomprises wrapping the plurality of turns of the first battery cellaround a mandrel having a diameter of at least two feet.
 78. The methodas defined in claim 77 wherein wrapping the plurality of turns of thefirst battery cell around a mandrel having a diameter of at least twofeet further comprises wrapping a plurality of turns of the firstbattery cell around the mandrel having a diameter of at least two feetand less than five feet.
 79. The method as defined in claim 78 whereinwrapping the plurality of turns of the first battery cell around themandrel having a diameter of at least two feet and less than five feetfurther comprises wrapping the battery cell around the mandrel having adiameter of approximately three feet.
 80. The method as defined in claim75 wherein cutting the wound battery system to create a stacked batterysystem further comprises: cutting the substantially cylindrical shapedconsecutively wound battery system on one side substantially parallelwith an axis of the cylindrical shape; and laying the cut substantiallycylindrical shaped consecutively wound battery system to besubstantially flat to become the stacked battery system with acircumference of the cylindrical shape becoming the length of thestacked battery cell.
 81. A method of producing multiple battery ropes,each rope having multiple cells, the method comprising: winding a firstset of battery cells around a mandrel, the first set of battery cellsbeing a first battery cell in each battery rope; cutting the first setof battery cells between them during the winding step; winding a secondset of battery cells around the first set of battery cells, the secondset of battery cells being a second battery in each battery rope;cutting the second set of battery cells between them during the windingstep; cutting the battery ropes to lay substantially flat and have asubstantially rectangular shape; separating a first battery rope, thefirst battery rope having multiple battery cells, from the secondbattery rope, the second battery rope having multiple battery cells. 82.The method of producing multiple battery ropes as defined in claim 81further comprising cutting one of the first and second battery ropes tohave a shorter length to adjust the amperage capacity.
 83. The method ofproducing multiple battery ropes as defined in claim 81 wherein cuttingthe first set of battery cells between them during the winding stepfurther comprises pulling anode and cathode material of the first set ofbattery cells over a razor during the winding process.
 84. The method ofproducing multiple battery ropes as defined in claim 83 furthercomprising, during the winding a first set of battery cells around amandrel, winding a plurality of electrolyte layers between the anode andcathode material, the electrolyte layers centered between dielectriclanes in the anode and cathode material defining the first and secondbattery ropes.
 85. The method of producing multiple battery ropes asdefined in claim 81 wherein cutting the second set of battery cellsbetween them during the winding step further comprises pulling anode andcathode material of the second set of battery cells over a razor duringthe winding process.
 86. The method of producing multiple battery ropesas defined in claim 85 further comprising, during the winding a firstset of battery cells around a mandrel, winding a plurality ofelectrolyte layers between the anode and cathode material, theelectrolyte layers centered between dielectric lanes in the anode andcathode material defining the first and second battery ropes.
 87. Themethod of producing multiple battery ropes as defined in claim 81further comprising, after the separating step, shooping ends of thebattery ropes.